US20110073365A1 - Press-clamping structure for press-clamping aluminum electric wire to terminal - Google Patents
Press-clamping structure for press-clamping aluminum electric wire to terminal Download PDFInfo
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- US20110073365A1 US20110073365A1 US12/742,989 US74298908A US2011073365A1 US 20110073365 A1 US20110073365 A1 US 20110073365A1 US 74298908 A US74298908 A US 74298908A US 2011073365 A1 US2011073365 A1 US 2011073365A1
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- caulking pieces
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/58—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation characterised by the form or material of the contacting members
- H01R4/62—Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
- H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
- H01R4/183—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section
- H01R4/184—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section comprising a U-shaped wire-receiving portion
- H01R4/185—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section comprising a U-shaped wire-receiving portion combined with a U-shaped insulation-receiving portion
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
- H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
- H01R4/188—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping having an uneven wire-receiving surface to improve the contact
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/02—Contact members
- H01R13/04—Pins or blades for co-operation with sockets
Definitions
- the present invention relates to a press-clamping structure for press-clamping an aluminum electric wire having a conductor portion where a plurality of strands of aluminum or aluminum alloy are twisted to a terminal.
- copper electric wires are used in wiring harnesses which are laid out on a vehicle such as an automotive vehicle.
- terminals are attached to the copper electric wires of the wiring harness, and terminals of this type are generally attached to the copper electric wires through press-clamping.
- the terminal which is press-clamped to the copper electric wire includes a bottom plate portion on which a conductor portion of the copper electric wire which is made up of a plurality of twisted strands of copper is placed and a pair of conductor caulking pieces which are provided consecutively to the bottom plate portion for holding therebetween the conductor portion placed on the bottom plate portion. Then, the conductor caulking pieces are caulked to the conductor portion in such a manner that distal end portions of the conductor caulking pieces are inserted into the conductor portion, so as to produce a state in which the strands of the conductor portion are partially embraced by the conductor caulking pieces, whereby the terminal is securely press-clamped to the conductor portion of the copper electric wire.
- a compressibility factor which can obtain compatibility between reduction in contact resistance between a conductor portion of an aluminum electric wire and a terminal and ensuring press-clamping strength of the terminal is regulated in accordance with a sectional area of the conductor portion.
- a compressibility factor of a conductor portion whose sectional area is less than 1.5 mm 2 is referred to as 50 to 70%
- a compressibility factor of a conductor whose sectional area is equal to or more than 1.5 mm 2 is referred to as 40 to 70%.
- a compressibility factor of a conductor portion in press-clamping of a copper electric wire to a terminal is typically referred to as 75 to 95%.
- FIGS. 5A and 5B there are provided two pairs of caulking pieces (barrels) that are to be caulked on to a conductor portion 202 of an aluminum electric wire 201 .
- holding caulking pieces 203 and electricity conducting caulking pieces 204 are caulked on to the conductor portion 202 by the use of a caulking tool in which a difference in level is provided in such a manner that the holding caulking pieces 203 which are situated on a proximal end side of the conductor portion 202 become higher than the electricity conducting caulking pieces 204 which are situated on a distal end side of the conductor portion 202 in such a state that both the caulking pieces are so caulked.
- a compressibility of the conductor portion 202 by the holding caulking pieces 203 is made to be substantially the same as a compressibility of a conductor portion of a copper electric wire in press-clamping of a terminal to the copper electric wire so as to ensure press-clamping strength while a compressibility factor of the conductor portion 202 by the electricity conducting caulking pieces 204 is made to be relatively high so as to reduce contact resistance.
- the compressibility factor of the conductor portion is increased overall, compared with the case of copper wire, and hence, it is inevitable that the press-clamping strength is reduced.
- the compressibility factor of the conductor portion can be made to differ between the location where the holding caulking pieces are caulked and the location where the electricity conducting caulking pieces are caulked, whereby the compressibility factor of the conductor portion in the location where the holding caulking pieces are caulked is made to be substantially the same as that of copper wire, so as to avoid the reduction in press-clamping strength of the terminal.
- the special caulking tool is necessary to caulk both the caulking pieces to the conductor portion in such a manner that the electricity conducting caulking pieces differs in height from the holding caulking pieces, and additionally, the heights at the two locations of the electricity conducting caulking pieces and the holding caulking pieces need to be managed, and to do this, costs have to be incurred exclusively.
- the invention has been made in view of the situations and an object thereof is to provide a press-clamping structure for press-clamping an aluminum electric wire to a terminal which can establish compatibility between reduction in contact resistance between a conductor portion of an aluminum electric wire and a terminal and ensuring press-clamping strength of the terminal with ease and in an ensured fashion.
- the object will be attained by a press-clamping structure for press-clamping between an aluminum electric wire and a terminal which will be described under (1) to (3) as below.
- a press-clamping structure including: an aluminum electric wire having a conductor portion in which a plurality of strands of aluminum or aluminum alloy are twisted; and a terminal which includes a bottom plate portion for placing the conductor portion thereon, and a pair of conductor caulking pieces which are provided consecutively to the bottom plate portion and are caulked to hold the conductor portion placed on the bottom plate portion, wherein the conductor caulking pieces are bent so that distal end portions of the conductor caulking pieces are inserted into the conductor portion, to thereby embrace part of the strands of the conductor portion, wherein at least one projection is formed on the bottom plate portion between the conductor caulking pieces, wherein outer surfaces of the respective distal end portions of the conductor caulking pieces are oriented towards the projection, and wherein the strands of the conductor portion are partially held between the outer surfaces of the respective distal end portions of the conductor caulking pieces and the projection.
- the strands of the conductor portion are partially held between the outer surfaces of the respective distal end portions of the conductor caulking pieces and the projection on the bottom plate portion. These strands are rubbed by the outer surfaces of the distal end portions of the conductor caulking pieces and the projection on the bottom plate portion when the conductor caulking pieces are caulked on to the conductor portion, and oxide layers formed on the surfaces of the strands are removed.
- the contact resistance between the conductor portion and the terminal can be reduced without increasing the compressibility factor of the conductor portion, so that the compressibility factor of the conductor portion can be made to be substantially the same as that of copper electric wire to thereby ensure the press-clamping strength of the terminal.
- the distal end portions of the conductor caulking pieces are inserted deeper into the conductor portion as the outer surfaces of the distal end portions of the conductor caulking pieces are oriented more towards the projection on the bottom plate portion, and this increases the contact area between the conductor caulking pieces and the conductor portion.
- stable electric conductivity can be obtained between the conductor portion and the terminal.
- friction is applied to the distal end portions of the conductor caulking pieces as a result of contact with the strands which are held in between the projection on the bottom plate portion and the distal end portions so inserted into the conductor portion. By the action of friction so applied, spring back in the conductor caulking pieces can be suppressed, whereby it becomes possible to maintain the contact resistance between the conductor portion and the terminal and the press-clamping strength of the terminal.
- the removing effect of the oxide layers on the strands can be enhanced.
- the compressibility factor of the conductor portion is gradually increased from the proximal end side to the distal end side, whereby the press-clamping strength is ensured on the proximal end side of the conductor portion, so as to avoid the application of load to the distal end side of the conductor portion where the contact resistance between the conductor portion and the terminal is reduced.
- the press-clamping structure for press-clamping an aluminum electric wire to a terminal the reduction in contact resistance between the aluminum electric wire and the terminal and ensuring the press-clamping strength of the terminal can easily be made compatible with each other.
- FIG. 1 is an exploded perspective view of an aluminum electric wire and a terminal which are used in a first embodiment of a press-clamping structure for press-clamping an aluminum electric wire to a terminal of the invention.
- FIG. 2 is a sectional view of the press-clamping structure shown in FIG. 1 .
- FIG. 3 is a sectional view of a second embodiment of a press-clamping structure for press-clamping an aluminum electric wire to a terminal.
- FIG. 4 is a sectional view taken along the line IV-IV in FIG. 3 .
- FIG. 5A is a plan view showing a known press-clamping structure for press-clamping an aluminum electric wire and a terminal.
- FIG. 5B is a side view of the press-clamping structure shown in FIG. 5A .
- FIG. 1 is an exploded perspective view of an aluminum electric wire and a terminal which are used in a first embodiment of a press-clamping structure for press-clamping an aluminum electric wire to a terminal of the invention
- FIG. 2 is a sectional view of the press-clamping structure shown in FIG. 1 .
- an aluminum electric wire 1 has a conductor portion 2 where a plurality of strands 3 of aluminum or aluminum alloy are twisted, and an outer circumference of the conductor portion 2 is covered with a sheath 4 formed from an insulation material.
- the sheath 4 is removed over a predetermined length at its terminating end portion so as to expose the conductor portion 2 , and a terminal 10 is connected to the terminating end portion through press-clamping.
- an aluminum alloy an alloy of aluminum and iron can be raised. In the case of this alloy being adopted, compared with a conductor of aluminum, the aluminum and iron alloy is easy to be elongated and strength (in particular, tensile strength) can be increased.
- the terminal 10 has a connecting portion 11 with a mating terminal (not shown) which is provided at a distal end portion and a holding portion 12 for holding the aluminum electric wire 1 which is provided at a proximal end portion thereof. Furthermore, the holding portion 12 has a conductor holding portion 13 for holding the conductor portion 2 of the aluminum electric wire 1 which is provided on a proximal end side, and a sheath holding portion 14 for holding the sheath 4 which is provided on a proximal end side thereof.
- the conductor holding portion 13 includes a bottom plate portion 20 for placing the conductor portion 2 thereon which is exposed at the terminating end portion of the aluminum electric wire 1 and a pair of conductor caulking pieces 21 which are provided consecutively to the bottom plate portion 20 for holding therebetween the conductor portion 2 which is placed on the bottom plate portion 20 .
- These conductor caulking pieces 21 are formed into a substantially U-shape on a section which is normal to an axial direction of the conductor portion 2 placed on the bottom plate portion 20 .
- the sheath holding portion 14 includes a bottom plate portion 22 on which the sheath 4 at the terminating end portion of the aluminum electric wire 1 is placed and a pair of sheath caulking pieces 23 which are provided consecutively to the bottom plate portion 22 for holding therebetween the sheath 4 placed on the bottom plate portion 22 .
- These sheath holding pieces 14 are, as with the conductor holding portion 13 , formed into a substantially U-shape in section.
- the bottom plate portion 22 of the sheath holding portion 14 is provided consecutively to a proximal end of the bottom plate portion 20 of the conductor holding portion 13 .
- One projection 24 is formed on the bottom plate portion 20 of the conductor holding portion 13 at a central portion between the pair of conductor caulking pieces 21 .
- the projection 24 is formed, for example, by hammering a conductive sheet metal of copper alloy which forms the bottom plate portion 20 .
- this projection 24 is provided over the area of the bottom plate portion 20 which extends over substantially the overall width of or interval between the conductor caulking pieces 21 .
- a plurality of projections may be provided in series along the axial direction over the area of the bottom plate portion 20 which extends over substantially the overall width of or interval between the conductor caulking pieces 21 .
- the terminal 10 is connected to the electric wire 1 through press-clamping by caulking the pair of conductor caulking pieces 21 of the conductor holding portion 13 on to the conductor portion 2 of the aluminum electric wire 1 placed on the bottom plate portion 20 of the conductor holding portion 13 and caulking the pair of sheath caulking pieces 23 of the sheath holding portion 14 on to the sheath 4 of the aluminum electric wire 1 placed on the bottom plate portion 22 of the sheath holding portion 14 .
- the pair of conductor caulking pieces 21 are caulked on to the conductor portion 2 substantially symmetrical with respect to a plane which includes the axis of the conductor portion 2 and which is substantially normal to the bottom plate portion 20 . More specifically, the pair of conductor caulking pieces 21 are bent in such a manner that distal end portions thereof are inserted into the conductor portion 2 individually, whereby the pair of conductor caulking pieces 21 are caulked on to the conductor portion 2 in such a state that the strands 3 of the conductor portion 2 are partially embraced by the distal end portions so inserted.
- the compressibility factor of the conductor portion 2 where the piece of conductor caulking pieces 21 is caulked is referred to as 50 to 90%.
- distal end portions of the respective sheath caulking pieces 23 may be made to bite into the sheath 4 or the distal end portion may only have to be wound round an outer circumference of the sheath 4 .
- Outer surfaces 21 a of the curled distal end portions of the respective conductor caulking pieces 21 which are inserted into the conductor portion 2 are oriented towards the projection 24 of the bottom plate portion 20 .
- the respective conductor caulking pieces 21 of the embodiment are formed longer than the caulking pieces of the known press-clamping structures in which the projecting end faces of the distal end portions of the caulking pieces are oriented towards the bottom plate portion and are caulked in such a manner as to be wound.
- the strands 3 of the conductor portion 2 are partially held in between the outer surfaces 21 a of the respective distal end portions of the conductor caulking pieces 21 and the projection 24 of the bottom plate portion 20 to be compressed.
- Some (part) of the strands 3 of the conductor portion 2 which are held in between the outer surfaces 21 a of the distal end portions of the respective conductor caulking pieces 21 are rubbed on their surfaces by the outer surfaces 21 a of the distal end portions of the conductor caulking pieces 21 and the projection 24 of the bottom plate portion 20 during the process of the conductor caulking pieces 21 being caulked on to the conductor portion 2 .
- oxide layers formed on the surfaces of the strands 3 in question are removed so as to expose their basic material of aluminum or aluminum alloy, whereby good electric conductivity is ensured between the conductor portion 2 and the terminal 10 .
- a sharp edge 24 a is provided on the projection 24 in an opposite position for facing the outer surfaces 21 a of the distal end portions of the respective conductor caulking pieces 21 .
- the oxide layers formed on the surfaces of the strands 3 can be cut off by the edges 24 a , whereby the oxide layers on the surfaces of the strands 3 can be removed in a more ensured fashion.
- some of the strands 3 of the conductor portion 2 are held in between the outer surfaces 21 a of the distal end portions of the conductor caulking pieces 21 and the projection 24 on the bottom plate portion 20 .
- These strands 3 are rubbed by the outer surfaces 21 a of the distal end portions of the conductor caulking pieces 21 and the projection 24 on the bottom plate portion 20 when the conductor caulking pieces 21 are caulked on to the conductor portion 2 , and the oxide layers formed on the surfaces of the strands 3 are removed.
- the contact resistance between the conductor portion 2 and the terminal 10 can be reduced without increasing the compressibility factor of the conductor portion 2 , so that the compressibility factor of the conductor portion 2 can be made to be substantially the same as that of copper electric wire to thereby ensure the press-clamping strength of the terminal 10 .
- the distal end portions of the conductor caulking pieces 21 are inserted deeper into the conductor portion 2 as the outer surfaces 21 a of the distal end portions of the conductor caulking pieces 21 are oriented more towards the projection 24 on the bottom plate portion 20 , and this increases the contact area between the conductor caulking pieces 21 and the conductor portion 2 .
- the sharp edges are provided in the locations on the projection 24 which oppositely face the outer surfaces 21 a of the distal end portions of the respective conductor caulking pieces 21 , and the edges 24 a so formed can enhance the oxide layer removing effect of removing the oxide layers on the strands 3 by the edges 24 a.
- FIG. 3 is a sectional view of a second embodiment of a press-clamping structure for press-clamping an aluminum electric wire to a terminal
- FIG. 4 is a sectional view taken along the line IV-IV in FIG. 3 .
- same reference numerals are imparted to similar members in terms of function to those of the press-clamping structure for press-clamping an aluminum electric wire to a terminal of the first embodiment, so as to omit the repeated description of the same features.
- a terminal 110 is connected to a terminating end portion of an aluminum electric wire 1 through press-clamping.
- the terminal 10 has a connecting portion with a mating terminal which is provided at a distal end portion and a holding portion for holding the aluminum electric wire 1 which is provided at a proximal end portion thereof.
- the holding portion has a conductor holding portion 113 for holding the conductor portion 2 of the aluminum electric wire 1 which is provided on a distal end side and a sheath holding portion for holding a sheath of the aluminum electric wire on a proximal end side thereof.
- the configuration of the sheath holding portion is similar to the terminal 10 of the press-clamping structure of the first embodiment that has been described above, and therefore, the description thereof will be omitted here.
- the conductor holding portion 113 includes a bottom plate portion 120 for placing the conductor portion 2 thereon which is exposed at the terminating end portion of the aluminum electric wire 1 and a pair of conductor caulking pieces 121 which are provided consecutively to the bottom plate portion 120 for holding therebetween the conductor portion 2 which is placed on the bottom plate portion 120 .
- These conductor caulking pieces 121 are formed into a substantially U-shape on a section which is normal to an axial direction of the conductor portion 2 placed on the bottom plate portion 120 .
- One projection 124 is formed on the bottom plate portion 120 of the conductor holding portion 113 at a central portion between the pair of conductor caulking pieces 121 .
- the projection 124 is provided over the area of the bottom plate portion 120 which extends over substantially the overall width of or interval between the conductor caulking pieces 121 , and as is shown in FIG. 4 , the height of the projection 124 is made to increase gradually from a proximal end side to a distal end side of the conductor portion 2 .
- the pair of conductor caulking pieces 121 are caulked on to the conductor portion 2 substantially symmetrical with respect to a plane which includes the axis of the conductor portion 2 and which is substantially normal to the bottom plate portion 120 . More specifically, the pair of conductor caulking pieces 121 are bent in such a manner that distal end portions thereof are inserted into the conductor portion 2 individually, whereby the pair of conductor caulking pieces 121 are caulked on to the conductor portion 2 in such a state that some of the strands 3 of the conductor portion 2 are embraced by the distal end portions so inserted.
- the compressibility factor of the conductor portion 2 in an area close to the proximal end side is made to be relatively low, while in an area close to the distal end side of the projection the compressibility factor of the conductor portion 2 is made to be relatively high.
- the press-clamping strength of the terminal 110 is ensured in the area where the compressibility factor of the conductor portion 2 is relatively low, and in the area where the compressibility factor of the conductor portion 2 is relatively high, the contact resistance between the conductor portion 2 and the terminal 110 is reduced.
- Outer surfaces 121 a of the curled distal end portions of the respective conductor caulking pieces 121 which are inserted into the conductor portion 2 are oriented towards the projection 124 of the bottom plate portion 120 .
- the strands 3 of the conductor portion 2 are partially held in between the outer surfaces 121 a of the distal end portions of the respective conductor caulking pieces 121 and the projection 124 of the bottom plate portion 120 to be compressed.
- Some (part) of the strands 3 of the conductor portion 2 which are held in between the outer surfaces 121 a of the distal end portions of the respective conductor caulking pieces 121 are rubbed on their surfaces by the outer surfaces 121 a of the distal end portions of the conductor caulking pieces 121 and the projection 124 of the bottom plate portion 120 during the process of the conductor caulking pieces 121 being caulked on to the conductor portion 2 .
- oxide layers formed on the surfaces of the strands 3 in question are removed so as to expose their basic material of aluminum or aluminum alloy, whereby good electricity conduction is ensured between the conductor portion 2 and the terminal 10 .
- the press-clamping structure of the second embodiment for press-clamping the aluminum electric wire 1 to the terminal 110 some of the strands 3 of the conductor portion 2 are held in between the outer surfaces 121 a of the distal end portions of the conductor caulking pieces 121 and the projection 124 on the bottom plate portion 120 . These strands 3 are rubbed by the outer surfaces 121 a of the distal end portions of the conductor caulking pieces 121 and the projection 124 on the bottom plate portion 120 when the conductor caulking pieces 121 are caulked on to the conductor portion 2 , and the oxide layers formed on the surfaces of the strands 3 are removed.
- the contact resistance between the conductor portion 2 and the terminal 110 can be reduced without increasing the compressibility factor of the conductor portion 2 , so that the compressibility factor of the conductor portion 2 can be made to be substantially the same as that of copper electric wire to thereby ensure the press-clamping strength of the terminal 110 .
- the distal end portions of the conductor caulking pieces 121 are inserted deeper into the conductor portion 2 as the outer surfaces 121 a of the distal end portions of the conductor caulking pieces 121 are oriented more towards the projection 124 on the bottom plate portion 120 , and this increases the contact area between the conductor caulking pieces 121 and the conductor portion 2 . By this configuration, stable electric conductivity can be obtained between the conductor portion 2 and the terminal 110 .
- the height of the projection 124 of the bottom plate portion 120 is made to increase gradually from the proximal end side to the proximal end side, whereby the compressibility factor of the conductor portion 2 is made to increase gradually from the proximal end side to the distal end side.
- the invention is not limited to the embodiments that is described above, and hence, the invention can be modified and/or improved as required.
- the shapes, dimensions, numeric values, forms, number, locations and the like of the respective constituent elements which are described in the embodiments are arbitrary and limited in no way, provided the invention can be attained.
- the present invention is utilized as a press-clamping structure for press-clamping an aluminum electric wire having a conductor portion where a plurality of strands of aluminum or aluminum alloy are twisted to a terminal.
Abstract
Description
- The present invention relates to a press-clamping structure for press-clamping an aluminum electric wire having a conductor portion where a plurality of strands of aluminum or aluminum alloy are twisted to a terminal.
- In general, copper electric wires are used in wiring harnesses which are laid out on a vehicle such as an automotive vehicle. In connecting wiring harnesses or a wiring harness with onboard equipment, terminals are attached to the copper electric wires of the wiring harness, and terminals of this type are generally attached to the copper electric wires through press-clamping.
- Typically, the terminal which is press-clamped to the copper electric wire includes a bottom plate portion on which a conductor portion of the copper electric wire which is made up of a plurality of twisted strands of copper is placed and a pair of conductor caulking pieces which are provided consecutively to the bottom plate portion for holding therebetween the conductor portion placed on the bottom plate portion. Then, the conductor caulking pieces are caulked to the conductor portion in such a manner that distal end portions of the conductor caulking pieces are inserted into the conductor portion, so as to produce a state in which the strands of the conductor portion are partially embraced by the conductor caulking pieces, whereby the terminal is securely press-clamped to the conductor portion of the copper electric wire.
- In recent years, in consideration of weight reduction of vehicles and easiness of recycling as well as shortage of copper resources, aluminum electric wires have been collecting many people's attention. However, in an aluminum electric wire when compared with copper, an oxide layer formed on an aluminum surface becomes thick, and there is a tendency of contact resistance between a conductor portion and a terminal becoming relatively high. As a means for reducing the contact resistance, there has been known a method in which respective conductor caulking pieces of a terminal are caulked strongly to the conductor portion so as to increase the compressibility factor of the conductor portion. According to this method, oxide layers on the respective strands making up the conductor portion are broken, whereby the contact resistance between the conductor portion and the terminal is reduced. Note that when used in this specification, the compressibility factor of the conductor portion is regulated as a ratio of a sectional area of the conductor portion before press-clamping to a sectional area of the conductor portion after press-clamping.
- However, stress applied to the conductor portion increases as the compressibility factor of the conductor increases. In addition, aluminum is inferior in mechanical strength to copper, and in the aluminum electric wire, when too large stress is laid on the conductor portion, the press-clamping strength of the terminal is deteriorated remarkably. Then, in press-clamping between an aluminum electric wire and a terminal, there have been proposed various press-clamping structure for press-clamping between an aluminum electric wire and a terminal for the purpose of making the reduction in contact resistance between the aluminum electric wire and the terminal with ensuring the press-clamping strength of the terminal (for example, refer to Patent Documents 1 and 2).
- In a press-clamping structure disclosed in Patent Document 1, a compressibility factor which can obtain compatibility between reduction in contact resistance between a conductor portion of an aluminum electric wire and a terminal and ensuring press-clamping strength of the terminal is regulated in accordance with a sectional area of the conductor portion. For example, a compressibility factor of a conductor portion whose sectional area is less than 1.5 mm2 is referred to as 50 to 70%, while a compressibility factor of a conductor whose sectional area is equal to or more than 1.5 mm2 is referred to as 40 to 70%. In addition, a compressibility factor of a conductor portion in press-clamping of a copper electric wire to a terminal is typically referred to as 75 to 95%.
- In a press-clamping structure disclosed in
Patent Document 2, as is shown inFIGS. 5A and 5B , there are provided two pairs of caulking pieces (barrels) that are to be caulked on to aconductor portion 202 of an aluminumelectric wire 201. In addition, holdingcaulking pieces 203 and electricity conducting caulkingpieces 204 are caulked on to theconductor portion 202 by the use of a caulking tool in which a difference in level is provided in such a manner that the holding caulkingpieces 203 which are situated on a proximal end side of theconductor portion 202 become higher than the electricity conducting caulkingpieces 204 which are situated on a distal end side of theconductor portion 202 in such a state that both the caulking pieces are so caulked. By this configuration, a compressibility of theconductor portion 202 by theholding caulking pieces 203 is made to be substantially the same as a compressibility of a conductor portion of a copper electric wire in press-clamping of a terminal to the copper electric wire so as to ensure press-clamping strength while a compressibility factor of theconductor portion 202 by the electricity conducting caulkingpieces 204 is made to be relatively high so as to reduce contact resistance. - [Patent Document 1] JP-A-2005-174896
- [Patent Document 2] JP-A-2005-50736
- In the press-clamping structure disclosed in Patent Document 1, the compressibility factor of the conductor portion is increased overall, compared with the case of copper wire, and hence, it is inevitable that the press-clamping strength is reduced. In contrast to this, in the press-clamping structure disclosed in
Patent Document 2, the compressibility factor of the conductor portion can be made to differ between the location where the holding caulking pieces are caulked and the location where the electricity conducting caulking pieces are caulked, whereby the compressibility factor of the conductor portion in the location where the holding caulking pieces are caulked is made to be substantially the same as that of copper wire, so as to avoid the reduction in press-clamping strength of the terminal. However, in the press-clamping structure disclosed inPatent Document 2, the special caulking tool is necessary to caulk both the caulking pieces to the conductor portion in such a manner that the electricity conducting caulking pieces differs in height from the holding caulking pieces, and additionally, the heights at the two locations of the electricity conducting caulking pieces and the holding caulking pieces need to be managed, and to do this, costs have to be incurred exclusively. - In addition, it is generally understood that spring back is produced in the caulking pieces which are caulked on to the conductor portion. In the press-clamping structures disclosed in
Patent Documents 1 and 2, the distal end portions of the caulking pieces are inserted into the conductor portion in such a manner that their projecting end faces are oriented towards the bottom plate portion. In the case of the caulking pieces which are caulked in the way described therein, the distal end portions are easily dislocated from the conductor portion, and spring back is easily produced. In addition, in the case of the conductor portion of the aluminum electric wire, aluminum which constitutes the respective strands is easier to produce stress relaxation than copper, and even in the event that spring back is produced in the caulking pieces to reduce the stress, it is difficult for them to restore the original positions. Due to this, a gap is produced between the caulking pieces and the conductor portion, whereby there is caused a risk that desired contact resistance and press-clamping strength cannot be obtained. - The invention has been made in view of the situations and an object thereof is to provide a press-clamping structure for press-clamping an aluminum electric wire to a terminal which can establish compatibility between reduction in contact resistance between a conductor portion of an aluminum electric wire and a terminal and ensuring press-clamping strength of the terminal with ease and in an ensured fashion.
- The object will be attained by a press-clamping structure for press-clamping between an aluminum electric wire and a terminal which will be described under (1) to (3) as below.
- (1) A press-clamping structure, including: an aluminum electric wire having a conductor portion in which a plurality of strands of aluminum or aluminum alloy are twisted; and a terminal which includes a bottom plate portion for placing the conductor portion thereon, and a pair of conductor caulking pieces which are provided consecutively to the bottom plate portion and are caulked to hold the conductor portion placed on the bottom plate portion, wherein the conductor caulking pieces are bent so that distal end portions of the conductor caulking pieces are inserted into the conductor portion, to thereby embrace part of the strands of the conductor portion, wherein at least one projection is formed on the bottom plate portion between the conductor caulking pieces, wherein outer surfaces of the respective distal end portions of the conductor caulking pieces are oriented towards the projection, and wherein the strands of the conductor portion are partially held between the outer surfaces of the respective distal end portions of the conductor caulking pieces and the projection.
- (2) The press-clamping structure according to (1), wherein the projection has a sharp edge in an opposed position for facing the outer surface of the distal end portion of the conductor caulking piece.
- (3) The press-clamping structure according to (1) or (2), wherein a height of the projection is made to gradually increase from a proximal end side to a distal end side of the conductor portion.
- According to the press-clamping structure set forth under (1), the strands of the conductor portion are partially held between the outer surfaces of the respective distal end portions of the conductor caulking pieces and the projection on the bottom plate portion. These strands are rubbed by the outer surfaces of the distal end portions of the conductor caulking pieces and the projection on the bottom plate portion when the conductor caulking pieces are caulked on to the conductor portion, and oxide layers formed on the surfaces of the strands are removed. By this action, the contact resistance between the conductor portion and the terminal can be reduced without increasing the compressibility factor of the conductor portion, so that the compressibility factor of the conductor portion can be made to be substantially the same as that of copper electric wire to thereby ensure the press-clamping strength of the terminal. In addition, the distal end portions of the conductor caulking pieces are inserted deeper into the conductor portion as the outer surfaces of the distal end portions of the conductor caulking pieces are oriented more towards the projection on the bottom plate portion, and this increases the contact area between the conductor caulking pieces and the conductor portion. By this configuration, stable electric conductivity can be obtained between the conductor portion and the terminal. Furthermore, friction is applied to the distal end portions of the conductor caulking pieces as a result of contact with the strands which are held in between the projection on the bottom plate portion and the distal end portions so inserted into the conductor portion. By the action of friction so applied, spring back in the conductor caulking pieces can be suppressed, whereby it becomes possible to maintain the contact resistance between the conductor portion and the terminal and the press-clamping strength of the terminal.
- According to the configuration of the press-clamping structure described under (2), the removing effect of the oxide layers on the strands can be enhanced.
- According to the configuration of the press-clamping structure described under (3), the compressibility factor of the conductor portion is gradually increased from the proximal end side to the distal end side, whereby the press-clamping strength is ensured on the proximal end side of the conductor portion, so as to avoid the application of load to the distal end side of the conductor portion where the contact resistance between the conductor portion and the terminal is reduced.
- According to the press-clamping structure for press-clamping an aluminum electric wire to a terminal, the reduction in contact resistance between the aluminum electric wire and the terminal and ensuring the press-clamping strength of the terminal can easily be made compatible with each other.
-
FIG. 1 is an exploded perspective view of an aluminum electric wire and a terminal which are used in a first embodiment of a press-clamping structure for press-clamping an aluminum electric wire to a terminal of the invention. -
FIG. 2 is a sectional view of the press-clamping structure shown inFIG. 1 . -
FIG. 3 is a sectional view of a second embodiment of a press-clamping structure for press-clamping an aluminum electric wire to a terminal. -
FIG. 4 is a sectional view taken along the line IV-IV inFIG. 3 . -
FIG. 5A is a plan view showing a known press-clamping structure for press-clamping an aluminum electric wire and a terminal. -
FIG. 5B is a side view of the press-clamping structure shown inFIG. 5A . - Hereinafter, preferred embodiments of a press-clamping structure for press-clamping an aluminum electric wire to a terminal will be described in detail based on the drawings.
-
FIG. 1 is an exploded perspective view of an aluminum electric wire and a terminal which are used in a first embodiment of a press-clamping structure for press-clamping an aluminum electric wire to a terminal of the invention, andFIG. 2 is a sectional view of the press-clamping structure shown inFIG. 1 . - As is shown in
FIG. 1 , an aluminum electric wire 1 has aconductor portion 2 where a plurality ofstrands 3 of aluminum or aluminum alloy are twisted, and an outer circumference of theconductor portion 2 is covered with asheath 4 formed from an insulation material. In the aluminum electric wire 1, thesheath 4 is removed over a predetermined length at its terminating end portion so as to expose theconductor portion 2, and aterminal 10 is connected to the terminating end portion through press-clamping. In addition, as a preferred specific example of an aluminum alloy, an alloy of aluminum and iron can be raised. In the case of this alloy being adopted, compared with a conductor of aluminum, the aluminum and iron alloy is easy to be elongated and strength (in particular, tensile strength) can be increased. - The terminal 10 has a connecting
portion 11 with a mating terminal (not shown) which is provided at a distal end portion and a holdingportion 12 for holding the aluminum electric wire 1 which is provided at a proximal end portion thereof. Furthermore, the holdingportion 12 has aconductor holding portion 13 for holding theconductor portion 2 of the aluminum electric wire 1 which is provided on a proximal end side, and asheath holding portion 14 for holding thesheath 4 which is provided on a proximal end side thereof. - The
conductor holding portion 13 includes abottom plate portion 20 for placing theconductor portion 2 thereon which is exposed at the terminating end portion of the aluminum electric wire 1 and a pair ofconductor caulking pieces 21 which are provided consecutively to thebottom plate portion 20 for holding therebetween theconductor portion 2 which is placed on thebottom plate portion 20. Theseconductor caulking pieces 21 are formed into a substantially U-shape on a section which is normal to an axial direction of theconductor portion 2 placed on thebottom plate portion 20. - The
sheath holding portion 14 includes abottom plate portion 22 on which thesheath 4 at the terminating end portion of the aluminum electric wire 1 is placed and a pair ofsheath caulking pieces 23 which are provided consecutively to thebottom plate portion 22 for holding therebetween thesheath 4 placed on thebottom plate portion 22. Thesesheath holding pieces 14 are, as with theconductor holding portion 13, formed into a substantially U-shape in section. In addition, thebottom plate portion 22 of thesheath holding portion 14 is provided consecutively to a proximal end of thebottom plate portion 20 of theconductor holding portion 13. - One
projection 24 is formed on thebottom plate portion 20 of theconductor holding portion 13 at a central portion between the pair ofconductor caulking pieces 21. Theprojection 24 is formed, for example, by hammering a conductive sheet metal of copper alloy which forms thebottom plate portion 20. In addition, thisprojection 24 is provided over the area of thebottom plate portion 20 which extends over substantially the overall width of or interval between theconductor caulking pieces 21. Note that a plurality of projections may be provided in series along the axial direction over the area of thebottom plate portion 20 which extends over substantially the overall width of or interval between theconductor caulking pieces 21. - The terminal 10 is connected to the electric wire 1 through press-clamping by caulking the pair of
conductor caulking pieces 21 of theconductor holding portion 13 on to theconductor portion 2 of the aluminum electric wire 1 placed on thebottom plate portion 20 of theconductor holding portion 13 and caulking the pair ofsheath caulking pieces 23 of thesheath holding portion 14 on to thesheath 4 of the aluminum electric wire 1 placed on thebottom plate portion 22 of thesheath holding portion 14. - As is shown in
FIG. 2 , the pair ofconductor caulking pieces 21 are caulked on to theconductor portion 2 substantially symmetrical with respect to a plane which includes the axis of theconductor portion 2 and which is substantially normal to thebottom plate portion 20. More specifically, the pair ofconductor caulking pieces 21 are bent in such a manner that distal end portions thereof are inserted into theconductor portion 2 individually, whereby the pair ofconductor caulking pieces 21 are caulked on to theconductor portion 2 in such a state that thestrands 3 of theconductor portion 2 are partially embraced by the distal end portions so inserted. The compressibility factor of theconductor portion 2 where the piece ofconductor caulking pieces 21 is caulked is referred to as 50 to 90%. In addition, there is imposed no specific limitation on the form of the pair ofsheath caulking pieces 23. For example, distal end portions of the respectivesheath caulking pieces 23 may be made to bite into thesheath 4 or the distal end portion may only have to be wound round an outer circumference of thesheath 4. -
Outer surfaces 21 a of the curled distal end portions of the respectiveconductor caulking pieces 21 which are inserted into theconductor portion 2 are oriented towards theprojection 24 of thebottom plate portion 20. Namely, the respectiveconductor caulking pieces 21 of the embodiment are formed longer than the caulking pieces of the known press-clamping structures in which the projecting end faces of the distal end portions of the caulking pieces are oriented towards the bottom plate portion and are caulked in such a manner as to be wound. In addition, thestrands 3 of theconductor portion 2 are partially held in between theouter surfaces 21 a of the respective distal end portions of theconductor caulking pieces 21 and theprojection 24 of thebottom plate portion 20 to be compressed. - Some (part) of the
strands 3 of theconductor portion 2 which are held in between theouter surfaces 21 a of the distal end portions of the respectiveconductor caulking pieces 21 are rubbed on their surfaces by theouter surfaces 21 a of the distal end portions of theconductor caulking pieces 21 and theprojection 24 of thebottom plate portion 20 during the process of theconductor caulking pieces 21 being caulked on to theconductor portion 2. By this rubbing action, oxide layers formed on the surfaces of thestrands 3 in question are removed so as to expose their basic material of aluminum or aluminum alloy, whereby good electric conductivity is ensured between theconductor portion 2 and the terminal 10. - Preferably, a
sharp edge 24 a is provided on theprojection 24 in an opposite position for facing theouter surfaces 21 a of the distal end portions of the respectiveconductor caulking pieces 21. The oxide layers formed on the surfaces of thestrands 3 can be cut off by theedges 24 a, whereby the oxide layers on the surfaces of thestrands 3 can be removed in a more ensured fashion. - In addition, by some of the
strands 3 of theconductor portion 2 being held in between theouter surfaces 21 a of the distal end portions of the respectiveconductor caulking pieces 21 and theprojection 24 of thebottom plate portion 20 to be compressed, friction is produced between the respectiveconductor caulking pieces 21 and thestrands 3. The friction so produced functions to prevent the dislocation of the distal end portions of the respectiveconductor caulking pieces 21 from theconductor portion 2. - According to the press-clamping structure of the embodiment for press-clamping the aluminum electric wire 1 to the terminal 10, some of the
strands 3 of theconductor portion 2 are held in between theouter surfaces 21 a of the distal end portions of theconductor caulking pieces 21 and theprojection 24 on thebottom plate portion 20. Thesestrands 3 are rubbed by theouter surfaces 21 a of the distal end portions of theconductor caulking pieces 21 and theprojection 24 on thebottom plate portion 20 when theconductor caulking pieces 21 are caulked on to theconductor portion 2, and the oxide layers formed on the surfaces of thestrands 3 are removed. By this action, the contact resistance between theconductor portion 2 and the terminal 10 can be reduced without increasing the compressibility factor of theconductor portion 2, so that the compressibility factor of theconductor portion 2 can be made to be substantially the same as that of copper electric wire to thereby ensure the press-clamping strength of the terminal 10. In addition, the distal end portions of theconductor caulking pieces 21 are inserted deeper into theconductor portion 2 as theouter surfaces 21 a of the distal end portions of theconductor caulking pieces 21 are oriented more towards theprojection 24 on thebottom plate portion 20, and this increases the contact area between theconductor caulking pieces 21 and theconductor portion 2. By this configuration, stable electric conductivity can be obtained between theconductor portion 2 and the terminal 10. Furthermore, friction is applied to the distal end portions of theconductor caulking pieces 21 as a result of contact with thestrands 3 which are held in between theprojection 24 on thebottom plate portion 20 and the distal end portions so inserted into theconductor portion 2. By the action of friction so applied, spring back in theconductor caulking pieces 21 can be suppressed, whereby it becomes possible to maintain the contact resistance between theconductor portion 2 and the terminal 10 and the press-clamping strength of the terminal 10. - Furthermore, according to the press-clamping structure of the embodiment for press-clamping the aluminum electric wire 1 to the terminal 10, the sharp edges are provided in the locations on the
projection 24 which oppositely face theouter surfaces 21 a of the distal end portions of the respectiveconductor caulking pieces 21, and theedges 24 a so formed can enhance the oxide layer removing effect of removing the oxide layers on thestrands 3 by theedges 24 a. -
FIG. 3 is a sectional view of a second embodiment of a press-clamping structure for press-clamping an aluminum electric wire to a terminal, andFIG. 4 is a sectional view taken along the line IV-IV inFIG. 3 . In the figures, same reference numerals are imparted to similar members in terms of function to those of the press-clamping structure for press-clamping an aluminum electric wire to a terminal of the first embodiment, so as to omit the repeated description of the same features. - As is shown in
FIG. 3 , in the press-clamping structure of this embodiment, a terminal 110 is connected to a terminating end portion of an aluminum electric wire 1 through press-clamping. The terminal 10 has a connecting portion with a mating terminal which is provided at a distal end portion and a holding portion for holding the aluminum electric wire 1 which is provided at a proximal end portion thereof. Furthermore, the holding portion has aconductor holding portion 113 for holding theconductor portion 2 of the aluminum electric wire 1 which is provided on a distal end side and a sheath holding portion for holding a sheath of the aluminum electric wire on a proximal end side thereof. The configuration of the sheath holding portion is similar to theterminal 10 of the press-clamping structure of the first embodiment that has been described above, and therefore, the description thereof will be omitted here. - The
conductor holding portion 113 includes abottom plate portion 120 for placing theconductor portion 2 thereon which is exposed at the terminating end portion of the aluminum electric wire 1 and a pair ofconductor caulking pieces 121 which are provided consecutively to thebottom plate portion 120 for holding therebetween theconductor portion 2 which is placed on thebottom plate portion 120. Theseconductor caulking pieces 121 are formed into a substantially U-shape on a section which is normal to an axial direction of theconductor portion 2 placed on thebottom plate portion 120. - One
projection 124 is formed on thebottom plate portion 120 of theconductor holding portion 113 at a central portion between the pair ofconductor caulking pieces 121. Theprojection 124 is provided over the area of thebottom plate portion 120 which extends over substantially the overall width of or interval between theconductor caulking pieces 121, and as is shown inFIG. 4 , the height of theprojection 124 is made to increase gradually from a proximal end side to a distal end side of theconductor portion 2. - The pair of
conductor caulking pieces 121 are caulked on to theconductor portion 2 substantially symmetrical with respect to a plane which includes the axis of theconductor portion 2 and which is substantially normal to thebottom plate portion 120. More specifically, the pair ofconductor caulking pieces 121 are bent in such a manner that distal end portions thereof are inserted into theconductor portion 2 individually, whereby the pair ofconductor caulking pieces 121 are caulked on to theconductor portion 2 in such a state that some of thestrands 3 of theconductor portion 2 are embraced by the distal end portions so inserted. - By the
projection 124 of thebottom plate portion 120 being made to gradually increase in height from the proximal end side to the distal end side, the compressibility factor of theconductor portion 2 in an area close to the proximal end side is made to be relatively low, while in an area close to the distal end side of the projection the compressibility factor of theconductor portion 2 is made to be relatively high. The press-clamping strength of the terminal 110 is ensured in the area where the compressibility factor of theconductor portion 2 is relatively low, and in the area where the compressibility factor of theconductor portion 2 is relatively high, the contact resistance between theconductor portion 2 and the terminal 110 is reduced. By the area where the press-clamping strength is ensured being situated on the proximal end side, a risk is avoided that load produced by pulling the aluminum electric wire is applied to the area on the distal end side where the contact resistance between theconductor portion 2 and the terminal 110 is reduced. -
Outer surfaces 121 a of the curled distal end portions of the respectiveconductor caulking pieces 121 which are inserted into theconductor portion 2 are oriented towards theprojection 124 of thebottom plate portion 120. In addition, thestrands 3 of theconductor portion 2 are partially held in between theouter surfaces 121 a of the distal end portions of the respectiveconductor caulking pieces 121 and theprojection 124 of thebottom plate portion 120 to be compressed. - Some (part) of the
strands 3 of theconductor portion 2 which are held in between theouter surfaces 121 a of the distal end portions of the respectiveconductor caulking pieces 121 are rubbed on their surfaces by theouter surfaces 121 a of the distal end portions of theconductor caulking pieces 121 and theprojection 124 of thebottom plate portion 120 during the process of theconductor caulking pieces 121 being caulked on to theconductor portion 2. By this rubbing action, oxide layers formed on the surfaces of thestrands 3 in question are removed so as to expose their basic material of aluminum or aluminum alloy, whereby good electricity conduction is ensured between theconductor portion 2 and the terminal 10. - In addition, by some of the
strands 3 of theconductor portion 2 being held in between theouter surfaces 121 a of the distal end portions of the respectiveconductor caulking pieces 121 and theprojection 124 of thebottom plate portion 120 to be compressed, friction is produced between the respectiveconductor caulking pieces 121 and thestrands 3. The friction so produced functions to prevent the dislocation of the distal end portions of the respectiveconductor caulking pieces 121 from theconductor portion 2. - Thus, as is described heretofore, according to the press-clamping structure of the second embodiment for press-clamping the aluminum electric wire 1 to the terminal 110, some of the
strands 3 of theconductor portion 2 are held in between theouter surfaces 121 a of the distal end portions of theconductor caulking pieces 121 and theprojection 124 on thebottom plate portion 120. Thesestrands 3 are rubbed by theouter surfaces 121 a of the distal end portions of theconductor caulking pieces 121 and theprojection 124 on thebottom plate portion 120 when theconductor caulking pieces 121 are caulked on to theconductor portion 2, and the oxide layers formed on the surfaces of thestrands 3 are removed. By this action, the contact resistance between theconductor portion 2 and the terminal 110 can be reduced without increasing the compressibility factor of theconductor portion 2, so that the compressibility factor of theconductor portion 2 can be made to be substantially the same as that of copper electric wire to thereby ensure the press-clamping strength of the terminal 110. In addition, the distal end portions of theconductor caulking pieces 121 are inserted deeper into theconductor portion 2 as theouter surfaces 121 a of the distal end portions of theconductor caulking pieces 121 are oriented more towards theprojection 124 on thebottom plate portion 120, and this increases the contact area between theconductor caulking pieces 121 and theconductor portion 2. By this configuration, stable electric conductivity can be obtained between theconductor portion 2 and the terminal 110. Furthermore, friction is applied to the distal end portions of theconductor caulking pieces 121 as a result of contact with thestrands 3 which are held in between theprojection 124 on thebottom plate portion 120 and the distal end portions so inserted into theconductor portion 2. By the action of friction so applied, spring back in theconductor caulking pieces 121 can be suppressed, whereby it becomes possible to maintain the contact resistance between theconductor portion 2 and the terminal 110 and the press-clamping strength of the terminal 110. - Furthermore, according to the press-clamping structure of the embodiment for press-clamping the aluminum electric wire 1 to the terminal 110, the height of the
projection 124 of thebottom plate portion 120 is made to increase gradually from the proximal end side to the proximal end side, whereby the compressibility factor of theconductor portion 2 is made to increase gradually from the proximal end side to the distal end side. By this configuration, the press-clamping strength of the terminal 110 is ensured on the proximal end side of theconductor 2 and a risk can be avoided that load is applied to the distal end side of the conductor where the contact resistance between theconductor portion 2 and the terminal 110. - In addition, the invention is not limited to the embodiments that is described above, and hence, the invention can be modified and/or improved as required. In addition to this, the shapes, dimensions, numeric values, forms, number, locations and the like of the respective constituent elements which are described in the embodiments are arbitrary and limited in no way, provided the invention can be attained.
- According to the present invention, it is utilized as a press-clamping structure for press-clamping an aluminum electric wire having a conductor portion where a plurality of strands of aluminum or aluminum alloy are twisted to a terminal.
Claims (3)
Applications Claiming Priority (3)
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JP2007298437A JP5024948B2 (en) | 2007-11-16 | 2007-11-16 | Crimp structure of aluminum wire and terminal |
JP2007-298437 | 2007-11-16 | ||
PCT/JP2008/070966 WO2009064009A2 (en) | 2007-11-16 | 2008-11-12 | Press-clamping structure for press-clamping aluminum electric wire to terminal |
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US8963006B2 US8963006B2 (en) | 2015-02-24 |
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US12/742,989 Active 2029-06-11 US8963006B2 (en) | 2007-11-16 | 2008-11-12 | Press-clamping structure for press-clamping aluminum electric wire to terminal |
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EP (1) | EP2208258B1 (en) |
JP (1) | JP5024948B2 (en) |
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US8905799B2 (en) | 2009-10-28 | 2014-12-09 | Yazaki Corporation | Press bond terminal |
US8851941B2 (en) | 2010-04-13 | 2014-10-07 | Yazaki Corporation | Crimping terminal and manufacturing of same |
US9484640B2 (en) | 2013-05-17 | 2016-11-01 | Sumitomo Wiring Systems, Ltd. | Wire with a crimp terminal with a bottom plate with an inclined portion and a raised portion |
US10167927B2 (en) | 2013-10-04 | 2019-01-01 | Thomas & Betts International Llc | Compression wire joints |
US9787031B2 (en) | 2015-07-21 | 2017-10-10 | Delphi Technologies, Inc. | Electrical connector with adjusted impedance |
US20210320435A1 (en) * | 2018-09-14 | 2021-10-14 | Weidmüller Interface GmbH & Co. KG | Busbar and busbar assembly for an electrical conductor |
US11824318B2 (en) * | 2018-09-14 | 2023-11-21 | Weidmüller Interface GmbH & Co. KG | Busbar and busbar assembly for an electrical conductor |
Also Published As
Publication number | Publication date |
---|---|
EP2208258B1 (en) | 2011-06-08 |
JP5024948B2 (en) | 2012-09-12 |
CN101861680A (en) | 2010-10-13 |
ATE512486T1 (en) | 2011-06-15 |
WO2009064009A2 (en) | 2009-05-22 |
WO2009064009A3 (en) | 2009-08-13 |
JP2009123620A (en) | 2009-06-04 |
US8963006B2 (en) | 2015-02-24 |
EP2208258A2 (en) | 2010-07-21 |
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